Optex Solar EcoOnline Performance+ User manual

EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 1
EcoOnline™Performance+
OKU Panel Solar Pool Heating System
Installation and User Manual - Revised 20/11/2020
Optex Solar Pty. Ltd.
ABN: 88 128 228 884
www.EcoOnline.com.au
email: [e-mail]
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved. This publication is protected by copyright law
and unless otherwise specified is for your personal and non-commercial use only. No part of this publication
may be reproduced or distributed by any process, electronic or otherwise, without the specific written
permission of Optex Solar Pty Ltd. Trademarks appearing in this manual are the sole property of Optex Solar
Pty Ltd or their respective owners. Nothing in this publication shall be construed as granting any express or
implied license to use any intellectual property of Optex Solar Pty Ltd otherwise than for personal and
non-commercial use only. Optex Solar Pty Ltd must not, to the full extent permitted by law, be held liable
for any claim, cost (including legal costs), damage, expense, loss (including fines, penalties, set-offs and
consequential loss) or liability arising from the use (or misuse) of any product described in this
publication, unless expressly provided otherwise in this publication. Information as well as any
products described in this publication are subject to change without notice.

EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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Contents
1Key Terms
2Pre-Installation Suitability and Safety Checklist
3Warranties
4System Sizing Guarantee
5Collector Sizing Guide
5.1 A Word on Transparent Bubble Pool Covers
6Pool Chemistry Compatibility Guide
7Pump Sizing Guide
7.1 A Word on Pump Sizing Choice
7.2 Solar Pump Sizing for Booster Systems
7.3 Filter Pump Sizing for Manual Systems
8Solar Line PVC Pipe Sizing Guide
9Roof Type Compatibility Guide
10 Wind and Climate Considerations
11 Collector Array Components
12 Additional Required Components (Not Supplied)
13 Required Tools
14 Safety When Working at Heights
14.1 Ladder Safety
15 Choosing a Place to Install the Collector Array
16 Collector Water Flow Configurations
16.1 Dual Header Panel Single Row Flow Configuration
16.2 Supply and Return Plumbing Options
16.3 Dual Header Panel Two Rows In-Parallel Configuration
16.4 Two Row Serpentine Flow Configuration
16.5 Parallel vs Serpentine Flow Configurations
16.6 Serpentine Flow for a Trapezoid or Parallelogram Array
16.7 Interconnect Panel Flow Configuration
16.8 Three Row In-Parallel Flow Configuration
16.9 Staggered Array Flow Configurations
16.10 Level Ground Mounting Configurations
16.11 Split Array at Similar Height Levels
16.12 Split Array at Substantially Different Heights
16.13 Return Line Configuration for Low Pitch Roof

EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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16.14 Preferred Bi-Directional Flow Configuration
16.15 Top Feed Flow Configuration for Non-Frost Areas
16.16 Top Feed Flow Configuration for Frost Areas
16.17 Plumbing Flow Configurations Not Recommended
17 Vacuum Release Location
18 Collector Panel Plumbing Connections
18.1 PVC Pipe Roof Fixings
19 Array Roof Fixing Configurations
19.1 Single or Multi-Row Metal Roof Fixings Wind Region A
19.2 Single or Multi-Row Metal Roof Fixings for Wind Regions B & C
19.3 Single or Multi-Row Tile Roof Fixings for Wind Region A & B
19.4 Low Wind Area Alternate Two Row Roof Fixings
19.5 Application of the PVC Coated Stainless Steel Straps
19.6 Three or More Row Roof Fixings
20 Tile Roof Aluminium Angle Mounting Options
20.1 Top Panel Tile Attachment
20.2 Two Row Panel to Panel Attachment
20.3 Two Row Mid Array Panel Attachment
20.4 Bottom Panel Tile Attachment
20.5 Stainless Steel Cable Anchor Point Option
20.6 Perforated Band Under-Tile Anchor Point
21 Corrugated Metal Roof Mounting Options
21.1 Mounting Options for Top or Bottom Angle Rail
21.2 Thermal Expansion Gaps for Aluminium Channels
21.3 Metal Roof Screw Selection and Method
22 Wind Proofing
22.1 Ultimate Peak Wind Loadings per Panel
22.2 Terrain Category Definitions
22.3 Wind Region Definitions
22.4 Frequency of Extra Fixings for Different Regions
22.5 Roof Edge High Wind Loading Zones
23 Seasoning Panels and Minimizing Contraction Issues
23.1 Mounting Procedure for Arrays 10 or Less Panels per Row
23.2 Mounting Procedure for Arrays 15 or Less Panels per Row
23.3 Mounting Arrays with 15 or More Panels per Row
24 Plumbing Diagram Configurations
24.1 Configuration 1: Independent/Separate System

EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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24.2 Configuration 2: Integrated Independent System
24.3 Notes on Teeing into the Suction Line for Configuration 2
24.4 Configuration 3: Manual/Timer/Motorized Valve System
24.5 Configuration 4: Booster/Retrofit System
25 Installing the Controller for Independent Systems
25.1 Installing the Roof/Hot Sensor
25.2 Installing the Pool/Cold Sensor
25.3 Extending Sensor Cords
26 Drain-Down, Frost Proofing and Winterization
26.1 Drain Down
26.2 Winterization
26.3 Installing a By-Pass Tube or By-Pass Ball Valve (18)
27 Optimizing Collector Pressure
27.1 Installing the Pressure Gauge
27.2 Pressure Check Procedure
27.3 Negative Pressure and Air Bubble Issues
27.4 Adjusting the 3 Way Valve for Manual Systems
27.5 Optimizing Pressure for Oversized Pumps
28 Checking for Balanced Water Flow
29 Service and Maintenance Schedule
29.1 Collector Repair Procedure
30 Important Installation Check List

EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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1Key Terms
This manual was written to follow guidelines and recommendations given in:
AS 3634 - 1989 Solar heating systems for swimming pools
AS 1170.2 - 2011 (Amend 2 Dec 2012) Structural design actions - Wind actions
‘HAZPAK’ produced by the work-cover authority
AS 3000 (2007) Sections 6.3, 6.4 & 6.5
AS 1926.1 & 1926.2 (2007) swimming pool safety - location of safety barrier
Please take the time to read this manual before starting any work. Particular attention should be given to text
contained in the following key terms.
Please note EcoOnline has a strong product safety policy; do not install products without reading safety guidelines in
the manual. Please report any product safety issues or near misses to [e-mail] no matter how trivial.
Refers to useful information for the optimal operation of the system
Indicates a SAFETY issue that is likely to cause injury or death if the user does not
follow the instructions.
Indicates a SAFETY issue that may cause injury or death if the user does not follow the
instructions.
Indicates a SAFETY issue that may cause injury or property damage if the user does
not follow the instructions
Refers to critically important information related to the correct functioning of the
system.
Why? Italic text is optional reading. Gives extra information and reasoning for recommendations that are
non-obvious and/or counter intuitive.

EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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2Pre-Installation Suitability and Safety Checklist
The following outlines mandatory suitability and safety requirements for installing this solar heating system. Please
read carefully, if any of the following requirements cannot be meet the system should NOT be purchased or
installed.
For ground level collector installations the installer MUST check child safety fence regulations
in the relevant state. Under no circumstances should collectors be installed so as to
compromise the effectiveness of a child pool or spa fence safety barrier by providing a
climbable object.
Building regulations vary from state to state and MUST override any instructions supplied in
this manual. It is the responsibility of the purchaser/installer to check that installations
comply with any relevant state laws and regulations.
At present this collector array system is not recommended for installations in cyclonic
regions C or D, or on houses situated on top of hills exposed to strong winds, or on second
story (or higher) roofs. Installations on tiles are for Wind Region A only.
Collectors are to be used with chlorinated (or otherwise sanitized) pool water ONLY. Do not
use collectors to heat fresh (untreated) water due to the potential for Legionaries bacteria
build up.
This appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have been
given supervision or instruction concerning use of the appliance by a person responsible for
their safety. Children should be supervised to ensure that they do not play with the appliance.
Due to the potential of falling from heights, mounting panels on a roof or structure at
heights should only be undertaken by a professional installer, unless you are accustomed
to and confident of performing the work safely. We strongly recommend the installer
invests in roof safety guard rails and a safety harness system, especially for DIY
applications.

EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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3Warranties
EcoOnline™ offers the following Warranties
35 year limited Warranty on all OKU collectors
2 year Warranty on Reltech Pool Pumps
3 year Warranty on Davey Pool Pumps
3 Year Warranty on Dontek and Ascon Controllers
See our Terms and Conditions page for further details: www.EcoOnline.com.au/terms-and-conditions
4System Sizing Guarantee
Sizing systems is difficult involving a lot of factors which we could get wrong. Hence in addition to the above
Warranties EcoOnline offers a System Sizing Guarantee as follows. If we sized your system (or you use our online
calculator) and you took our advice and you aren’t happy with the system’s performance (heat output), then you can
purchase up to 25% more panels originally supplied by EcoOnline up to two years after your original purchase and
we will ship the items free of shipping charges.
5Collector Sizing Guide
An interactive collector sizing calculator and pool water temperature simulator can be found on our website at:
www.EcoOnline.com.au/pool-heating-sizing-calculator
www.EcoOnline.com.au/pool-water-temperature-simulator
5.1 A Word on Transparent Bubble Pool Covers
EcoOnline recently carried out a full pool heating loading technical study including performance data on transparent
bubble pool covers. We found that while pool covers produce a moderate heating effect by themselves, they
produced a much larger pool temperature boost when used in conjunction with a solar pool heater due to
synergistic effects. So much so that if you’re running a solar pool heater and not using a pool cover you are missing
out on surprisingly large temperature gains - see link below for the summaries:
www.EcoOnline.com.au/how-warm-can-a-pool-get-with-a-solar-heater-and-cover
Customer please note: WARRANTY IS VOID if collectors are installed:
without a vacuum release valve on the return line,
or a non-return valve on the solar pump outlet (with 6mm drain hole in flap),
or if panels are run at pressures other than a maximum of ± 1psi (6kPa),
or if the collectors are installed well below the water level (max 1.5m).
Why? Such installations will expose the collectors to strong fatiguing positive/negative
pressures. These situations will have detrimental effects on the collectors which will limit
lifetimes and can also result in significant shrinkage of the collectors which would put
strain on roof attachments.

EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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So if you’ve used a pool cover before and had disappointing results, we highly recommend you try using a cover
again after you install our solar pool heating system.
6Pool Chemistry Compatibility Guide
7Pump Sizing Guide
7.1 A Word on Pump Sizing Choice
The quick reference tables below outline conservative Australian Standard pump sizing recommendations.
There is a range of pump powers one can choose from. If thermal system efficiency is important then choose a pump
at the high end to produce high flow rate; take care not to over-pressurizing your system (see Optimizing Collector
Pressure below). If electrical efficiency (COP factor) is important to you then choose a pump near the lowest power
range. To help you understand the potential savings from such choices we have created an interactive pump sizing
simulator which can be found on our website at:
www.EcoOnline.com.au/oku-performance-pool-heating-pump-sizing
However, if you go with a lower power pump you’ll need the following:
A slightly larger collector area; the pump sizing calculator will let you know by how much.
You will need to check with the pump manufacture that your chosen pump can still prime reliably at your
pump height.
We highly recommend you use a by-pass line to help your pump prime reliably, see Installing a By-Pass Tube
or By-Pass Ball Valve section below.
Lastly you may need to run your main filter pump in the afternoon to help mix the warm water if your pool
volume turnover falls below the 50% - 75% range.
Please note the silicon joiners used in the system are not compatible with acidic pool/spa
water (pH less than 7.2). Sodium Carbonate must be added to protect the system from acidic
pH (<7). pH should be maintained between 7.2-7.8 for maximum longevity. If required Sodium
Bisulphate acid can be used to keep the pH down.
Why? Acidic water with pH less than 7.0 has excess free H+ ions which like to bond to and
hence break apart silicon bonds.

EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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Australian Standard Input Pump Power for Independent Systems
Pool
Water
Volume
Min - Max
Recommended
Flow
For 1st Story Install (3m):
For 2nd Story Install (6m):
Min - Max
Input Pump Watts
Min - Max
Input Pump Watts
20,000 L
50 - 67 L/min
270 - 300 Watts
350 - 380 Watts
25,000 L
63 - 83 L/min
300 - 330 Watts
370 - 410 Watts
30,000 L
75 - 100 L/min
320 - 370 Watts
400 - 450 Watts
35,000 L
88 - 117 L/min
340 - 400 Watts
420 - 480 Watts
40,000 L
100 - 133 L/min
360 - 440 Watts
450 - 520 Watts
45,000 L
113 - 150 L/min
390 - 470 Watts
470 - 560 Watts
50,000 L
125 - 167 L/min
420 - 510 Watts
500 - 600 Watts
55,000 L
138 - 183 L/min
450 - 560 Watts
530 - 640 Watts
60,000 L
150 - 200 L/min
470 - 600 Watts
560 - 690 Watts
65,000 L
163 - 217 L/min
500 - 640 Watts
600 - 740 Watts
70,000 L
175 - 233 L/min
530 - 700 Watts
620 - 790 Watts
75,000 L
188 - 250 L/min
570 - 740 Watts
660 - 840 Watts
80,000 L
200 - 267 L/min
600 - 790 Watts
700 - 900 Watts
If you don’t know your pools water volume you can look it up from the table supplied below based on the total
water area and average depth:
7.2 Solar Pump Sizing for Booster Systems
Pool Water area vs Average Depth Conversion Table
Average depth
Waters Area
1.3 m
1.4 m
1.45 m
1.5 m
1.55 m
1.6 m
1.65 m
1.7 m
1.8 m
10 m2
13000 L
14000 L
14500 L
15000 L
15500 L
16000 L
16500 L
17000 L
18000 L
15 m2
19500 L
21000 L
21750 L
22500 L
23250 L
24000 L
24750 L
25500 L
27000 L
20 m2
26000 L
28000 L
29000 L
30000 L
31000 L
32000 L
33000 L
34000 L
36000 L
25 m2
32500 L
35000 L
36250 L
37500 L
38750 L
40000 L
41250 L
42500 L
45000L
30 m2
39000 L
42000 L
43500 L
45000 L
46500 L
48000 L
49500 L
51000 L
54000 L
35 m2
45500 L
49000 L
50750 L
52500 L
54250 L
56000 L
57750 L
59500 L
63000 L
40 m2
52000 L
56000 L
58000 L
60000 L
62000 L
64000 L
66000 L
68000 L
72000 L
45 m2
58500 L
63000 L
65250 L
67500 L
69750 L
72000 L
74250 L
76500 L
81000 L
50 m2
65000 L
70000 L
72500 L
75000 L
77500 L
80000 L
82500 L
85000 L
90000 L
55 m2
71500 L
77000 L
79750 L
82500 L
85250 L
88000 L
90750 L
93500 L
99000 L
For booster type systems you should choose a pump at or just below the minimum
specs in the table above. Why? The take off point for solar is already pressurized by the
filter pump, hence a smaller pump should be used.

EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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7.3 Filter Pump Sizing for Manual Systems
8Solar Line PVC Pipe Sizing Guide
The table below will help you choose the correct size PVC pipe for the solar lines running to and from your roof. On
the roof, we generally recommend 32 PVC (DN30), except for larger multiple row arrays with a secondary header
pipe feeding each row, for which you should use 40 PVC (DN40). Coming down the roof the pipe size can then be
adapted to the pipe size you have for your solar line ground run i.e. 40 PVC (DN40) or 50 PVC (DN50).
Recommended PVC Piping Sizing for Solar Pool Heating System Lines
Anticipated Flow Rate
Absolute Minimum
Ideal PVC Pipe Size
Maximum Pipe Size
70 Litres/min
20 PVC (DN20)
25 PVC (DN25)
32 PVC (DN30)
120 Litres/min
25 PVC (DN25)
32 PVC (DN30)
40 PVC (DN40)
200 Litres/min
32 PVC (DN30)
40 PVC (DN40)
50 PVC (DN50)
250 Litres/min
40 PVC (DN40)
50 PVC (DN50)
65 PVC (DN65)
400 Litres/min
50 PVC (DN50)
65 PVC (DN65)
80 PVC (DN80)
880 Litres/min
80 PVC (DN80)
100 PVC (DN100)
125 PVC (DN125)
For manual type systems running off the main pool filter pump, please check that the
filter pump is large enough to accommodate the extra load of supplying water to the
collectors at the required pump height + a 1 meter pressure drop across the collector
array. Why? Filter pumps are geared for flow not pump height, solar pumps are geared
specifically for roof solar applications.
If the distance from the pool to the roof collector area is more than 10m we recommend
you use the next size up PVC pipe.